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NASA NTRS2004

Research Performed within the Non-Destructive Evaluation Team at NASA Glenn Research Center

Non-destructive testing is essential in many fields of manufacturing and research in order to perform reliable examination of potentially damaged materials and parts without destroying the inherent structure of the materials. Thus, the Non-Destructive Evaluation (NDE) Team at NASA Glenn Research Center partakes in various projects to improve materials testing equipment as well as analyze materials, material defects, and material deficiencies. Due to the array of projects within the NDE Team at this time, five research aims were supplemental to some current projects. A literature survey of "DE and testing methodologies as related to rocks was performed. Also, Mars Expedition Rover technology was assessed to understand the requirements for instrumentation in harsh space environments (e.g. temperature). Potential instrumentation and technologies were also considered and documented. The literature survey provided background and potential sources for a proposal to acquire funding for ultrasonic instrumentation on board a future Mars expedition. The laboratory uses a Santec Systems AcousticScope AS200 acoustography system. Labview code was written within the current program in order to improve the current performance of the acoustography system. A sample of Reinforced Carbon/Carbon (RCC) material from the leading edge of the space shuttle underwent various non-destructive tests (guided wave scanning, thermography, computed tomography, real time x-ray, etc.) in order to characterize its structure and examine possible defects. Guided wave scan data of a ceramic matrix composite (CMC) panel was reanalyzed utilizing image correlations and signal processing variables. Additional guided wave scans and thermography were also performed on the CMC panel. These reevaluated data and images will be used in future presentations and publications. An additional axis for the guided wave scanner was designed, constructed, and implemented. This additional axis allowed incremental spacing of the previously fixed transducers for ultrasonic velocity measurements.

Burns, Erin A.↗

NASA NTRS2000

Composite Flywheels Assessed Analytically by NDE and FEA

As an alternative to expensive and short-lived lead-acid batteries, composite flywheels are being developed to provide an uninterruptible power supply for advanced aerospace and industrial applications. Flywheels can help prevent irregularities in voltage caused by power spikes, sags, surges, burnout, and blackouts. Other applications include load-leveling systems for wind and solar power facilities, where energy output fluctuates with weather. Advanced composite materials are being considered for these components because they are significantly lighter than typical metallic alloys and have high specific strength and stiffness. However, much more research is needed before these materials can be fully utilized, because there is insufficient data concerning their fatigue characteristics and nonlinear behavior, especially at elevated temperatures. Moreover, these advanced types of structural composites pose greater challenges for nondestructive evaluation (NDE) techniques than are encountered with typical monolithic engineering metals. This is particularly true for ceramic polymer and metal matrix composites, where structural properties are tailored during the processing stages. Current efforts involving the NDE group at the NASA Glenn Research Center at Lewis Field are focused on evaluating many important structural components, including the flywheel system. Glenn's in-house analytical and experimental capabilities are being applied to analyze data produced by computed tomography (CT) scans to help assess the damage and defects of high-temperature structural composite materials. Finite element analysis (FEA) has been used extensively to model the effects of static and dynamic loading on aerospace propulsion components. This technique allows the use of complicated loading schemes by breaking the complex part geometry into many smaller, geometrically simple elements.

Abdul-Aziz, Ali↗

NASA NTRS2001

Rapid Prototyping Integrated With Nondestructive Evaluation and Finite Element Analysis

Most reverse engineering approaches involve imaging or digitizing an object then creating a computerized reconstruction that can be integrated, in three dimensions, into a particular design environment. Rapid prototyping (RP) refers to the practical ability to build high-quality physical prototypes directly from computer aided design (CAD) files. Using rapid prototyping, full-scale models or patterns can be built using a variety of materials in a fraction of the time required by more traditional prototyping techniques (refs. 1 and 2). Many software packages have been developed and are being designed to tackle the reverse engineering and rapid prototyping issues just mentioned. For example, image processing and three-dimensional reconstruction visualization software such as Velocity2 (ref. 3) are being used to carry out the construction process of three-dimensional volume models and the subsequent generation of a stereolithography file that is suitable for CAD applications. Producing three-dimensional models of objects from computed tomography (CT) scans is becoming a valuable nondestructive evaluation methodology (ref. 4). Real components can be rendered and subjected to temperature and stress tests using structural engineering software codes. For this to be achieved, accurate high-resolution images have to be obtained via CT scans and then processed, converted into a traditional file format, and translated into finite element models. Prototyping a three-dimensional volume of a composite structure by reading in a series of two-dimensional images generated via CT and by using and integrating commercial software (e.g. Velocity2, MSC/PATRAN (ref. 5), and Hypermesh (ref. 6)) is being applied successfully at the NASA Glenn Research Center. The building process from structural modeling to the analysis level is outlined in reference 7. Subsequently, a stress analysis of a composite cooling panel under combined thermomechanical loading conditions was performed to validate this process.

Abdul-Aziz, Ali↗

NASA NTRS2001

Nondestructive Evaluation Methodologies Developed for Certifying Composite Flywheels

Manufacturing readiness of composite rotors and certification of flywheels depend in part on the maturity of nondestructive evaluation (NDE) technology for process optimization and quality assurance, respectively. At the NASA Glenn Research Center, the capabilities and limitations of x-ray-computed tomography and radiography, as well as advanced ultrasonics were established on NDE ring and rotor standards with electrical discharge machining (EDM) notches and drilled holes. Also, intentionally seeded delamination, tow break, and insert of bagging material were introduced in hydroburst-rings to study the NDE detection capabilities of such anomalies and their effect on the damage tolerance and safe life margins of subscale rings and rotors. Examples of possible occurring flaws or anomalies in composite rings as detected by NDE and validated by destructive metallography are shown. The general NDE approach to ensure the quality of composite rotors and to help in the certification of flywheels is briefly outlined.

Baaklini, George Y.↗

NASA NTRSDate not supplied

Nondestructive Evaluation for the Space Shuttle's Wing Leading Edge

The loss of the Space Shuttle Columbia highlighted concerns about the integrity of the Shuttle's thermal protection system, which includes Reinforced Carbon-Carbon (RCC) on the leading edge. This led NASA to investigate nondestructive evaluation (NDE) methods for certifying the integrity of the Shuttle's wing leading edge. That investigation was performed simultaneously with a large study conducted to understand the impact damage caused by errant debris. Among the many advanced NDE methods investigated for applicability to the RCC material, advanced digital radiography, high resolution computed tomography, thermography, ultrasound, acoustic emission and eddy current systems have demonstrated the maturity and success for application to the Shuttle RCC panels. For the purposes of evaluating the RCC panels while they are installed on the orbiters, thermographic detection incorporating principal component analysis (PCA) and eddy current array scanning systems demonstrated the ability to measure the RCC panels from one side only and to detect several flaw types of concern. These systems were field tested at Kennedy Space Center (KSC) and at several locations where impact testing was being conducted. Another advanced method that NASA has been investigating is an automated acoustic based detection system. Such a system would be based in part on methods developed over the years for acoustic emission testing. Impact sensing has been demonstrated through numerous impact tests on both reinforced carbon-carbon (RCC) leading edge materials as well as Shuttle tile materials on representative aluminum wing structures. A variety of impact materials and conditions have been evaluated including foam, ice, and ablator materials at ascent velocities as well as simulated hypervelocity micrometeoroid and orbital debris impacts. These tests have successfully demonstrated the capability to detect and localize impact events on Shuttle's wing structures. A first generation impact sensing system has been designed for the next Shuttle flight and is undergoing final evaluation for deployment on the Shuttle's first return to flight. This system will employ wireless accelerometer sensors that were qualified for other applications on previous Shuttle flights. These sensors will be deployed on the wing's leading edge to detect impacts on the RCC leading edge panels. The application of these methods will help to insure the continued integrity of the Shuttle wing's leading edge system as the Shuttle flights resume and until their retirement.

Eric I Madaras↗

NASA NTRS2006

Validation of Ultrasound Imaging to Rule-out Thoracic Trauma on the International Space Station

Introduction: Aboard the International Space Station (ISS) an intra-thoracic injury may be disastrous to the crew member if the diagnosis is missed or even delayed. Pneumothorax and hemothorax commonly seen in trauma patients; the diagnosis is usually confirmed by chest X-ray or computed tomography. In this study, the ability of ultrasound to rule out pneumothorax by the presence "lung sliding" and hemothorax by the absence of pleural fluid was validated. Methods: The research activities were approved by the NASA Johnson Space Center Committee for the Protection of Human Subjects, and the participating crewmembers signed informed consent prior to the activity. ISS crewmembers received 2-hours of "hands on" ultrasound training 8 months prior to the on-orbit ultrasound exam. Baseline ultrasound images of the thorax were acquired on the crewmebers of Increment 8 and 9 prior to launch from Bakonur, Russia. Ultrasound examination of the thorax were performed on crewmembers at 30 day intervals (n=??) throughout their flight. Post flight images were acquired on or about landing day 10. Ultrasound images were acquired using the ISS Health Research Facility ultrasound system and examined by experts on the ground to rule out the presence of pneumothorax and hemothorax. Results: The presence of "lung sliding" which excludes pneumothorax, was seen in all subjects. The absence of pleural fluid, which excludes hemothorax was seen in all subjects. The optimal position between sonographer and patient under microgravity conditions and the amount and type of training for a non-physician crew medical officer for these procedures was also established for this procedure. Conclusion: Ultrasound can be performed on orbit under microgravity condition to rule thoracic trauma, such as pneumothorax and hemothorax.

Hamilton, Douglas R.↗

NASA NTRS2006

Development of the Gecko (Pachydactylus turneri) Animal Model during Foton M-2 to Study Comparative Effects of Microgravity in Terrestrial and Aquatic Organisms

Terrestrial organisms exposed to microgravity during spaceflight experience degeneration in bone, muscle, and possibly other tissues that require gravity-mediated mechanical stimulation for normal regenerative growth. In the Gecko experiment aboard Foton M-2, we flew for the first time, five terrestrial Pachydactylus turneri specimens to develop a model of microgravity effects comparable to the newt Pleurodeles waltl, a well-established model organism for spaceflight. These lower vertebrate species have similar body plans and size, are poikilothermic, have tissue regenerative ability, and are adapted to moderate periods of fasting. Furthermore the gecko (Pachydactylus) can also survive prolonged periods without water. In pre-flight control experiments and after a 16-day Foton M-2 spaceflight without food or water, the geckos were recovered and showed no apparent negative health effects. However, detailed analysis of bone mass and architecture by micro Computed Tomography { pCT), showed that both synchronous control and spaceflight animals lost significant amounts of cancellous bone in the distal femur and humerus relative to basal controls. In addition, cell cycle analysis of 30h post-flight liver tissue reveals a shift of DNA content from G2 and S to G1, both in spaceflight and synchronous controls. Together, these results suggest that housing conditions alone induce rapid catabolism of cancellous bone and reduced normal tissue regeneration. Further use of the gecko Puchydactylus turneri as a spaceflight model requires modification of housing conditions, possibly by including water and food, or changing other factors such as eliminating housing stresses to obtain stable bone structure and tissue regeneration during spaceflight experiments.

Almeida, E. A.↗

NASA NTRS2007

Oxidation Through Coating Cracks of SiC-Protected Carbon/Carbon

The oxidation of SiC-protected carbon/carbon through machined slots and naturally occurring craze cracks in the SiC was studied. The slot and crack geometries were characterized, and the subsurface oxidation of the carbon/carbon substrate at temperatures of 1000 to 1300 C in air was assessed using weight change, x-ray computed tomography, and optical microscopy of sections. Rate constants were derived from these measurements and compared with a two-step diffusion control model of carbon oxidation. Oxidation kinetic measurements on both the specimens with machined slots and with naturally occurring craze cracks showed good agreement with the model.

Jacobson, Nathan S.↗

NASA NTRS2007

Oxidation Through Coating Cracks of SiC-Protected Carbon/Carbon

Jacobson, Nathan S.↗

NASA NTRS1992

Method for improved prediction of bone fracture risk using bone mineral density in structural analysis

A non-invasive in-vivo method of analyzing a bone for fracture risk includes obtaining data from the bone such as by computed tomography or projection imaging which data represents a measure of bone material characteristics such as bone mineral density. The distribution of the bone material characteristics is used to generate a finite element method (FEM) mesh from which load capability of the bone can be determined. In determining load capability, the bone is mathematically compressed, and stress, strain force, force/area versus bone material characteristics are determined.

Cann, Christopher E.↗

NASA NTRS2008

Low-Cost, Large C-SiC Blisk Fabrication

C-SiC composites offer unique properties for propulsion applications. However, fabrication of low-cost, thick, large scale C-SiC disk for integrally bladed disk (blisk) applications has not been established yet. MER has demonstrated a new process to address this issue. Polymer-based processing was employed for interfacial coatings, consolidation and densification. Up to 40" O.C., 2" thick C-SiC composite processing was established, yielding in excess of 1.8 g/cu cm density. Computer tomography (CT) scans on the 40" O.D., 2" thick C-SiC disk showed no visible delamination, and good density uniformity. Stress-rupture testing in air was conducted at 2200 F, 2400 F and 2550 F.

Kowbel, W.↗

NASA NTRS2008

Oxidation Through Coating Cracks of SiC-Protected Carbon/Carbon

Jacobson, Nathan S.↗

NASA NTRS2008

Impact Resistance of Uncoated SiC/SiC Composites

Two-dimensional woven SiC/SiC composites fabricated by melt infiltration method were impact tested at room temperature and at 1316 C in air using 1.59-mm diameter steel-ball projectiles at velocities ranging from 115 to 400 m/s. The extent of substrate damage with increasing projectile velocity was imaged and analyzed using optical and scanning electron microscopy, and non-destructive evaluation (NDE) methods such as pulsed thermography, and computed tomography. The impacted specimens were tensile tested at room temperature to determine their residual mechanical properties. Results indicate that at 115 m/s projectile velocity, the composite showed no noticeable surface or internal damage and retained its as-fabricated mechanical properties. As the projectile velocity increased above this value, the internal damage increased and mechanical properties degraded: At velocities >300 m/s, the projectile penetrated through the composite, but the composite retained approx.50% of the ultimate tensile strength of the as-fabricated composite and exhibited non-brittle failure. Predominant internal damages are delamination of fiber plies, fiber fracture and matrix shearing.

Bhatt, Ramakrishna T.↗

NASA NTRS2009

Nondestructive Evaluation (NDE) for Characterizing Oxidation Damage in Cracked Reinforced Carbon-Carbon (RCC)

In this study, coated reinforced carbon-carbon (RCC) samples of similar structure and composition as that from the NASA space shuttle orbiter's thermal protection system were fabricated with slots in their coating simulating craze cracks. These specimens were used to study oxidation damage detection and characterization using nondestructive evaluation (NDE) methods. These specimens were heat treated in air at 1143 and 1200 C to create cavities in the carbon substrate underneath the coating as oxygen reacted with the carbon and resulted in its consumption. The cavities varied in diameter from approximately 1 to 3 mm. Single-sided NDE methods were used since they might be practical for on-wing inspection, while x-ray micro-computed tomography (CT) was used to measure cavity sizes in order to validate oxidation models under development for carbon-carbon materials. An RCC sample having a naturally-cracked coating and subsequent oxidation damage was also studied with x-ray micro-CT. This effort is a follow-on study to one that characterized NDE methods for assessing oxidation damage in an RCC sample with drilled holes in the coating.

Roth, Don J.↗

NASA NTRS2009

NDE for Characterizing Oxidation Damage in Reinforced Carbon-Carbon

In this study, coated reinforced carbon-carbon (RCC) samples of similar structure and composition as that from the NASA space shuttle orbiter s thermal protection system were fabricated with slots in their coating simulating craze cracks. These specimens were used to study oxidation damage detection and characterization using NDE methods. These specimens were heat treated in air at 1143 and 1200 C to create cavities in the carbon substrate underneath the coating as oxygen reacted with the carbon and resulted in its consumption. The cavities varied in diameter from approximately 1 to 3 mm. Single-sided NDE methods were used since they might be practical for on-wing inspection, while x-ray micro-computed tomography (CT) was used to measure cavity sizes in order to validate oxidation models under development for carbon-carbon materials. An RCC sample having a naturally-cracked coating and subsequent oxidation damage was also studied with x-ray micro-CT. This effort is a follow-on study to one that characterized NDE methods for assessing oxidation damage in an RCC sample with drilled holes in the coating. The results of that study are briefly reviewed in this article as well. Additionally, a short discussion on the future role of simulation to aid in these studies is provided.

Roth, Don J.↗

NASA NTRS2007

Millimeter Wave Holographical Inspection of Honeycomb Composites

Multi-layered composite structures manufactured with honeycomb, foam or balsa wood cores are finding increasing utility in a variety of aerospace, transportation, and infrastructure applications. Due to the low conductivity and inhomogeneity associated with these composites standard nondestructive testing (NDT) methods are not always capable of inspecting their interior for various defects caused during the manufacturing process or as a result of in-service loading. On the contrary, microwave and millimeter wave NDT methods are well-suited for inspecting these structures since signals at these frequencies readily penetrate through these structures and reflect from different interior boundaries revealing the presence of a wide range of defects such as disbond, delamination, moisture and oil intrusion, impact damage, etc. Millimeter wave frequency spectrum spans 30 GHz - 300 GHz with corresponding wavelengths of 10 - 1 mm. Due to the inherent short wavelengths at these frequencies, one can produce high spatial resolution images of these composites either using real-antenna focused or synthetic-aperture focused methods. In addition, incorporation of swept-frequency in the latter method (i.e., holography) results in high-resolution three-dimensional images. This paper presents the basic steps behind producing such images at millimeter wave frequencies and the results of two honeycomb composite panels are demonstrated at Q-band (33-50 GHz). In addition, these results are compared to previous results using X-ray computed tomography.

Case, J. T.↗

NASA NTRS2009

A Biomechanical Approach to Assessing Hip Fracture Risk

Bone loss in microgravity is well documented, but it is difficult to quantify how declines in bone mineral density (BMD) contribute to an astronaut's overall risk of fracture upon return. This study uses a biomechanical approach to assessing hip fracture risk, or Factor of Risk (Phi), which is defined as the ratio of applied load to bone strength. All long-duration NASA astronauts from Expeditions 1-18 were included in this study (n=25), while crewmembers who flew twice (n=2) were treated as separate subjects. Bone strength was estimated based on an empirical relationship between areal BMD at the hip, as measured by DXA, and failure load, as determined by mechanical testing of cadaver femora. Fall load during a sideways fall was calculated from a previously developed biomechanical model, which takes into account body weight, height, gender, and soft tissue thickness overlying the lateral aspect of the hip that serves to attenuate the impact force. While no statistical analyses have been performed yet, preliminary results show that males in this population have a higher FOR than females, with a post- flight Phi of 0.87 and 0.36, respectively. FOR increases 5.1% from preflight to postflight, while only one subject crossed the fracture "threshold" of Phi = 1, for a total of 2 subjects with a postflight Phi > 1. These results suggest that men may be at greater risk for hip fracture due largely in part to their relatively thin soft tissue padding as compared to women, since soft tissue thickness has the highest correlation (R(exp 2)= .53) with FOR of all subject-specific parameters. Future work will investigate changes in FOR during recovery to see if baseline risk levels are restored upon return to 1-g activity. While dual x-ray absorptiometry (DXA) is the most commonly used clinical measure of bone health, it fails to provide compartment-specific information that is useful in assessing changes to bone quality as a result of microgravity exposure. Peripheral quantitative computed tomography (pQCT) accomplishes this by imaging transverse "slices" of the long bones. This project was a re-analysis of a 90 day bed rest study to determine if changes to cortical and trabecular compartments could be detected in the distal tibia with statistical significance using a new pQCT image analysis method. Nearly all changes in bone mineral density (BMD) and cross sectional area (CSA) measures were seen with statistical significance, with the exception of a change in cortical BMD. Total bone CSA increased by 1.1 % (p =0.01), cortical CSA decreased by - 5.6% (p<0.001) and trabecular CSA increased by 1.76% (p=0.007); the combination of which suggests bone resorption occurred at the endocortical surface in response to mechanical unloading by bed rest. Furthermore, total BMD and trabecular BMD decreased (-3.8%, p=0.001 and -2.8%, p =0.007, respectively), while decreases in cortical BMD failed to reach significance (-1.2%, p=0.07). Given that compartment-specific changes are seen with significance and are likely to influence bone strength, it is recommended that pQCT remain a standard measure used in bed rest because it provides a unique measure by which to better evaluate the efficacy of countermeasures to microgravity-induced bone loss.

Ellman, Rachel↗

NASA NTRS2009

Traditional Cardiovascular Risk Factors as Predictors of Cardiovascular Events in the U.S. Astronaut Corps

Risk prediction equations from the Framingham Heart Study are commonly used to predict the absolute risk of myocardial infarction (MI) and coronary heart disease (CHD) related death. Predicting CHD-related events in the U.S. astronaut corps presents a monumental challenge, both because astronauts tend to live healthier lifestyles and because of the unique cardiovascular stressors associated with being trained for and participating in space flight. Traditional risk factors may not hold enough predictive power to provide a useful indicator of CHD risk in this unique population. It is important to be able to identify individuals who are at higher risk for CHD-related events so that appropriate preventive care can be provided. This is of special importance when planning long duration missions since the ability to provide advanced cardiac care and perform medical evacuation is limited. The medical regimen of the astronauts follows a strict set of clinical practice guidelines in an effort to ensure the best care. The purpose of this study was to evaluate the utility of the Framingham risk score (FRS), low-density lipoprotein (LDL) and high-density lipoprotein levels, blood pressure, and resting pulse as predictors of CHD-related death and MI in the astronaut corps, using Cox regression. Of these factors, only two, LDL and pulse at selection, were predictive of CHD events (HR(95% CI)=1.12 (1.00-1.25) and HR(95% CI)=1.70 (1.05-2.75) for every 5-unit increase in LDL and pulse, respectively). Since traditional CHD risk factors may lack the specificity to predict such outcomes in astronauts, the development of a new predictive model, using additional measures such as electron-beam computed tomography and carotid intima-media thickness ultrasound, is planned for the future.

Halm, M. K.↗